Thermal Management Practices for Forklift Lithium Packs

As electric forklifts are widely adopted in warehousing, manufacturing and logistics distribution scenarios, the thermal management of lithium packs has become a core factor affecting operation safety, battery service life and overall operation cost. Improper thermal control operations may accelerate battery performance attenuation, or even bring hidden risks of abnormal overheating under long-term high-intensity working conditions.

The first basic practice is to conduct daily temperature monitoring for lithium packs. Operators need to check the surface temperature of the battery at regular intervals during operation, confirm the temperature stays within the reasonable working range, and avoid continuous full-load operation for a long time in environments with temperature higher than 40 degrees Celsius. Before starting daily operation, staff should check whether the heat dissipation channels are blocked by dust or sundries, to make sure the air inlets and outlets of passive or active heat dissipation modules are unobstructed.

The second practice is to arrange scenario-adaptive thermal control configurations. For high-frequency two-shift operation scenarios with long continuous working hours, users can equip matched auxiliary thermal control devices to stabilize the battery temperature during charging and discharging. When performing charging operations, do not place the battery close to any heat source, do not charge in enclosed spaces exposed to direct sunlight, and reserve sufficient ventilation space around the battery pack.

The third regular practice is to carry out periodical professional inspection. Within specified maintenance cycles, professional technicians need to check the working status of all temperature sensing modules, confirm that the data feedback of each temperature measuring point is accurate, so as to avoid the hidden trouble of overheating caused by temperature monitoring failure. Technicians also need to clean the dust accumulated on the shell of the battery pack and the gaps of heat dissipation components in time to prevent dust accumulation from reducing heat dissipation efficiency.

BYD Forklift has added relevant standardized thermal management operation guidance in its public user operation manual, to help users better maintain the stable operation of the lithium power system. If you need customized thermal management solution for your own forklift fleet, you can contact Jianshu New Energy for professional technical support, and you can send related consultation emails to 17399989919@163.com.

Following these standardized thermal management practices can effectively prolong the cycle life of lithium packs, reduce the incidence of thermal related hidden dangers, lower the overall life cycle cost of electric forklifts, and provide stable and reliable power support for daily industrial handling operations.